Technological advances and applications of rotational hydrodynamic cavitation reactors for process intensification: A comprehensive review

Abstract

Hydrodynamic cavitation (HC) is increasingly recognized as an advanced process intensification technology due to its energy-efficient, environmentally friendly, and inherently safe characteristics. The advanced rotational hydrodynamic cavitation reactor (ARHCR), a novel type of hydrodynamic cavitation reactor (HCR), offers significantly enhanced treatment efficiency and scalability compared to traditional HCRs. This superior performance is attributed to its innovative structural design, which makes it highly effective for a wide range of environmental and chemical applications. To advance the development and application of ARHCRs, this review provides a comprehensive summary of recent progress in both academic research and industrial practices. It also elucidates the cavitating flow mechanism of two distinct types of reactors. This review examines five key applications of ARHCRs, including water treatment, removal of microorganisms, sludge disintegration, lignocellulose pretreatment, and biodiesel production. It examines the influence of critical operating parameters, including reactor geometry and dimensions, rotational speed, flow rate, temperature, and pollutant or feedstock concentration. Additionally, the economic feasibility of these applications is thoroughly analyzed. While only a limited number of studies address the feasibility of industrial-scale implementation, ARHCRs have demonstrated significantly greater economic efficiency for most applications compared to traditional methods. Future research should focus on exploring the flow mechanisms, reactor design, synergistic effects, scaling-up principles, optimization of operating parameters, and durability of ARHCRs. The strengths, weaknesses, opportunities, and threats (SWOT) of the ARHCR-based processes are analyzed using a SWOT matrix. This review aims to provide valuable insights that will guide further research and facilitate the industrialization of this innovative reactor technology. © 2025 Elsevier B.V.